3

Product Information

Shielding Gas
The right gas working for you
02 Contents

Contents.

3 Choosing the right gas

6 Welding processes

8 Product range

10 Gases for carbon and low-alloy steels

14 Gases for stainless steels

18 Gases for aluminium, copper and titanium alloys

20 Plasma welding and cutting

21 MIG brazing

22 Purging or root backing

24 Frequently asked questions

26 Health and safety

28 Supply options

30 Services

ACCURA®, CORGON®, CRONIGON®, LASGON®, LINDATA®, LIPROTECT®, LISY®tec MISON® SECCURA® and VARIGON® are registered trademarks of the Linde Group.

Can a shielding gas affect the weld quality?
Choosing the right gas.
For many people, the sole role of the shielding gas
is to protect the finished weld from the effects of
oxygen and nitrogen in the atmosphere. What isn’t
widely understood is that selecting the right shielding weld’s strength, ductility, toughness and corrosion resistance.
gas for the job can bring many more benefits.
The choice of the shielding gas can affect:
• the weld metal properties, such as strength, corrosion resistance
and toughness
• the weld bead shape and size
• the weld porosity and fusion
• welding speed and amount of spatter
Choosing the right gas 03
Ar Ar/He
The addition of helium to the shielding gas results in a hotter welding arc
than that produced from pure argon.
Carbon dioxide Argoshield Heavy Argoshield Universal
17.1g 8.6g 8.6g
Weld metal properties
Although the weld metal properties are primarily controlled by the
composition of the consumable, the shielding gas can influence the
Adding oxygen and/or carbon dioxide to a shielding gas for MIG
welding carbon steel increases its oxidation potential. In general, for
a given welding wire, the higher the oxidation potential of a shielding
gas, the lower the strength and toughness of the weld. This occurs
because the oxygen and carbon dioxide in the shielding gas increase
the number of oxide inclusions and reduce the level of materials such as
manganese and silicon in the weld metal.
When MIG welding stainless steel, the amount of carbon dioxide in the
shielding gas has an effect on the corrosion resistance of the resulting
weld metal. In particular, carbon transfer into the weld from the gas
can produce unacceptably high carbon content in the welded areas. If
those welds are exposed to excessively high heat input during welding
or elevated service temperatures, the material is likely to become
sensitised to intergranular corrosion due to carbide precipitation. When
welding ‘L’ grade stainless steels, it is important to keep the carbon
dioxide level in the gas below 3% to ensure carbon pickup doesn’t
increase carbon in the weld metal above the 0.03% specified maximum
for the weld metal in order to prevent sensitisation. Standard stainless
steels (non-‘L’-grade) also benefit from a limited CO2 content because
surface oxidation is greatly reduced.
04 Choosing the right gas

Impact values at -20ºC (joules) % CO2 in Gas

0.040
Argoshield Light
0.035

0.030

% Carbon in weld metal

Argoshield Universal
Maximum limit in stainless steel
0.025

0.020
Argoshield Heavy
0.015

0.010
Carbon dioxide
0.005

10 20 30 40 50 60 70 80 1 2 3 4 5 6 7 8

% CO2 in Gas

The addition of carbon dioxide and oxygen to argon for MIG welding
carbon steels increases weld fluidity – allowing faster welding speed
and improving the stability of metal transfer.

Weld shape and quality

Although shielding gases with lower levels of oxygen and/or carbon
dioxide usually result in weld metal having higher mechanical
properties, these welds can suffer from greater instances of fusion
defects than those made from gases with higher oxidation potentials.
Shielding gases with low oxidation potentials produce weld beads with
a very narrow wineglass or finger-like bead profile. Adding carbon
dioxide to the shielding gas has a significant effect on the shape of the
weld bead, making it wider and more rounded, so reducing the chances
of fusion defects occurring.
Another good example of how the shielding gas can affect the quality or
integrity of the weld metal is the welding of aluminium. When welding
thick aluminium sections with pure argon as the shielding gas, porosity,
lack of penetration and fusion defects can occur. The addition of helium
to the argon shielding gas can significantly reduce these defects.
This is because the high thermal conductivity of helium results in more
energy being transferred into the weld. This in turn produces a hotter
weld pool, resulting in improved fusion and slower freezing times,
allowing any trapped gas more time to escape.
Another way in which the shielding gas can improve the weld quality is
by reducing the level of weld reinforcement. Weld reinforcement can be
a problem because it increases the stresses at the toes of a weld and in
severe cases can lead to cracking at the edges of the weld, particularly
under fatigue conditions. The normal method of removing or reducing
the reinforcement is to grind off the surplus weld metal, but this is both
costly and time-consuming. A correctly balanced shielding gas reduces
the surface tension of the weld metal, allowing the solidifying weld
pool to sink and resulting in a weld with lower reinforcement.

Operational performance
There are many ways in which a shielding can improve welding-process
performance. For example, the addition of hydrogen to argon when
TIG welding-austenitic stainless steel results in a more fluid arc, which
allows welding speeds to be significantly increased.
Choosing the right gas 05
The use of carbon dioxide when MIG welding carbon steels can cause
large amounts of spatter to be ejected from the weld pool. By using an
argon/18-20% carbon dioxide mixture, the amount of spatter can be
halved and by moving to an argon/12% carbon dioxide/2% oxygen
mixture, this value can be halved again. Removing spatter after welding
is both costly and can cause problems if the component is subsequently
painted or coated, as the small marks left by the spatter show up as
surface imperfections.
06 Welding processes
Which is the right process for you?
Welding processes.
The four most common welding processes are:
MIG (Metal Inert Gas) welding, also known as MAG (Metal Active Gas)
welding and GMAW (Gas Metal Arc Welding). In Europe, the term ‘MIG’ is
used only when a totally inert gas shield like argon is used, and ‘MAG’
when the shielding gas also contains active constituents, such as
carbon dioxide or oxygen
TIG (Tungsten Inert Gas) welding, also known as
GTAW (Gas Tungsten Arc Welding)
FCAW (Flux Cored Arc Welding)
MMA (Manual Metal Arc) welding, also known as
SMAW (Shielded Metal Arc Welding)
Each process has strengths and weaknesses; some can be automated,
others cannot. But how does each compare?
MIG
MIG versus MMA
• MIG is a high-productivity continuous process requiring little down time
• MIG can be used semi-automatically, automatically and robotically;
MMA is manual
• MIG is suitable for a wide range of common materials. MMA electrodes
are available primarily for ferrous materials and nickel alloys
• MIG requires a shielding gas; MMA requires no shielding gas
• MIG suffers from draughts affecting the gas shield. MMA is ideally
suited to outside and site work because the electrode coating
generates its own shielding gas
• MIG doesn’t create a slag cover; MMA requires the slag to be removed
• Welding speeds are much quicker with MIG
• With MIG, about 98% of the consumable weight is converted into weld
metal compared to about 65% for MMA

MIG
MIG versus TIG
• Skill levels for MIG welding are lower than those required for TIG
• Welding speeds for MIG are generally about double those for TIG
• Weld costs per unit length are much higher in TIG welding
• Generally, defect levels in TIG welds are lower than those for MIG, and
TIG tends to be used for intricate work and where a high-quality finish
is required
MIG versus FCAW
• FCAW is mainly limited to carbon and low-alloy steels and some types
of stainless steel
• Positional welding can be easier using some flux-cored wires than
with MIG
• MIG requires a shielding gas; some types of cored wire require a
shielding gas but others don’t
• Flux-cored wires are much less efficient, about 65–80% compared
with 98% for MIG
• MIG and FCAW welding speeds are very similar
• MIG doesn’t create a slag cover but FCAW requires the slag to
be removed
Welding processes 07
TIG
TIG versus MMA
• TIG can be used manually or automatically whereas MMA is a
manual process
• TIG can be used for all metals and alloys whereas MMA is limited.
However for alloys where MMA electrodes are available, they can be
tailored to suit the composition of the parent material
• TIG requires a separate shielding gas but MMA produces its own
shielding gas
• TIG can suffer from draughts disrupting the gas shield. MMA is ideally
suited to outside and site work because it generates its own shielding gas
• TIG doesn’t create a slag cover and needs little post-weld cleaning but
MMA requires the slag to be removed
• MMA is predominantly a manual process whereas FCAW can be used
semi-automatically, automatically and robotically
• MMA electrodes and flux-cored wires cover very similar ferrous,
stainless steel and hardfacing materials
• FCAW may be operated with or without a separate gas shield
(depending on the type). MMA never requires a separate shielding gas
• Self-shielded cored wires are ideal for site work, as is MMA
• Welding speeds are much quicker with FCAW, so joint completion
times are much faster.
• With MMA, only about 65% of the consumable weight is converted
into weld metal compared with up to 80% for FCAW
08 Product range

Providing the right gas for you.

Product range.

Product range

Argoshield Light
Argoshield Heavy
Specshield 20% CO2
Argoshield Universal
Carbon Dioxide
Specshield 2.5% CO2
Stainshield Heavy
Stainshield Universal
Stainshield Light
Stainshield TIG
Specshield 5% H2
Specshield 2.5% N2
Specshield 13% He, 4% H2
Pureshield Argon
Alushield Light
Alushield Universal
Alushield Heavy
Specshield 35% H2

For any application, it is important to choose the

right shielding gas. BOC provides an extensive
shielding gas range to meet all requirements. To
make the choice easier, the following pages present
the attributes of each shielding gas for different
materials, allowing you to select those that are most
important for your application.

Our product range includes some shielding gases that have been
tailored to offer added benefits. These have been specially developed
to optimise the performance of the shielding gas in one or more
respects.

BOC shielding gases provide you with a competitive advantage by

reducing manufacturing costs through increasing production, reducing
reject rates and improving quality.

All our products are proven mixtures offering the highest quality time
and time again, meeting or exceeding ISO 14175:2008 standards.

For further information on the standards please refer to the BOC

publication ‘White Paper – ISO 14175:2008’.
 Product range 09

Nominal composition (%) ISO 14175:2008 Material/Process

Ar He CO2 O2 H2 N2 NO
93 5 2 M14 - ArCO - 5/2 MIG welding carbon steel
78 20 2 M26 - ArCO - 20/2
80 20 M21 - ArC - 20
86 12 2 M24 - ArCO - 12/2
100 C-C
97.5 2.5 M12 - ArC - 2.5 MIG welding stainless steel
60 38 2 M12 - ArHeC - 38/2
43 55 2 M12 - HeArC - 43/2
13.5 85 1.5 M12 - HeArC - 13.5/1.5
98 2 R1 - ArH - 2 TIG welding various materials
95 5 R1 - ArH - 5
97.5 2.5 N2 -ArN - 2.5
83 13 4 R1 - ArHeH - 13/5
100 I1 - Ar MIG and TIG welding various materials
70 30 I3 - ArHe - 30
50 50 I3 - ArHe - 50
25 75 I3 - ArHe - 75
65 35 R2 - ArH - 35 Plasma cutting
10 Gases for carbon and low-alloy steels

The right gases for welding a wide range of steels.

Gases for carbon and low-alloy steels.

Steel forms the largest and most widely used group
of structural and engineering alloys, and more steel
is used in manufacturing than all other metals and
alloys put together.
MIG welding
MIG welding is the most common process for welding carbon and low-
alloy steels. The high productivity obtained by this semi-automatic
process makes it ideally suited to the construction and manufacturing of
steel structures and components.

Steel is a term generally used to describe an extensive range of iron- Argon-based gas mixtures are commonly used to weld carbon and low-
carbon alloys. The carbon content may be up to about 2% but the alloy steels. These mixtures contain additions of active gases, oxygen
majority of steels contain less than 1% carbon. and/or carbon dioxide to improve welding performance. How much of
these active gases is added depends on the application.
Simple steels, with carbon (and silicon and manganese) as the main
alloying additions are often called carbon steels or carbon-manganese
steels, whereas steels with small amounts of additional alloying
additions (such as chromium, nickel and molybdenum) are called low
alloy steels. Low-alloy steels are used in low- and high-temperature
service and in creep- and wear-resisting applications.
 Gases for carbon and low-alloy steels 11

Gases for carbon and low-alloy steels

Welding Spatter Reduced Porosity Fusion Penetration Ease of use Optimum thickness
speed control slag island control range (mm)
Argoshield Light 0.6 to 5
Specshield 20% CO2 4 to 12+
Argoshield Universal 2 to 12
Argoshield Heavy 4 to 12+

The greater the number of dots, the better the gas performs.

Argoshield Light Argoshield Universal

This three component shielding gas is designed predominantly for
welding thinner materials. The addition of oxygen increases arc stability
minimising the amount of spatter. This makes the product ideal for
welding components that are painted or powder coated after welding.
The faster welding speeds achievable with this gas coupled with a low
heat input also help to reduce welding distortion.
Again this product can suffer from lack of sidewall fusion and inter-run
porosity when welding thicker materials.
Specshield 20% CO2
Specshield 20% CO2 produces welds with very good penetration and
sidewall fusion, especially when welding thicker materials. This mixture
performs very well in both dip and spray but is on the upper limit of CO2
content for pulse welding.
The high CO2 content helps cope with surface contamination such as
oil, moisture or rust reducing pre-weld cleaning so reducing the cost of
manufacture.
This three component mixture designed for maximum performance
and ease of use giving it a high welder acceptance so reducing the
instances of weld defects.
Ideal for semi-automatic, automatic and robotic applications, the gas
produces smooth flat welds with good penetration and sidewall
fusion as well as low spatter reducing the need for rework and
increasing productivity.
Welding speeds are high over a wide range of welding conditions
making it the first choice product when productivity and low levels of
distortion important.
Argoshield Heavy
This three component mixture produces welds with good penetration
and sidewall fusion ideal for welding thicker materials were weld
strength is key. The addition of oxygen to the mixture reduces surface
tension, lowering reinforcement levels and chances of undercut while
improving arc stability.

The higher CO2 content produces more spatter and slag islands which
can represent a considerable additional cost. Welding sheet material is
more difficult with this gas as it is easier to burn though.
12 Gases for carbon and low-alloy steels

Alloy flux-cored and metal-cored arc welding

Welding Spatter Porosity Fusion Penetration Ease

speed control control of use
Carbon
dioxide
Specshield
20% CO2

The greater the number of dots, the better the gas performs.

Flux-cored and metal-cored arc welding

Flux-cored arc welding and metal-cored arc welding processes are Carbon dioxide
similar to MIG welding, except that the welding wires are tubular and This gas is suitable for use with many brands of flux-cored wire.
contain flux powders and/or metal powders rather than being solid. Generally produces more spatter and particulate fume.

Consumable manufacturers blend their wires to suit one or two
shielding gas mixtures; check which are recommended before
commencing welding.
Specshield 20% CO2
For use with flux-cored wires recommended for use with ‘mixed gas’. In
general it gives lower fume and spatter levels than pure carbon dioxide.
Lower fume levels can improve the workplace environment as well as
improve the well being of the workforce.
 Gases for carbon and low-alloy steels 13

TIG welding

Welding Ease of Porosity Fusion Penetration Ease of use Thickness range

speed arc striking control (mm)
Pureshield Argon 0 to 5
Alushield Light 1.6 to 10+
Alushield Universal 3 to 10+

The greater the number of dots, the better the gas performs.

TIG welding

TIG welding is not commonly used for carbon steels, but it is used more
for welding low-alloy steels where high-precision joints and excellent
surface finish are more important than high productivity. Since the
TIG process uses a non-consumable tungsten electrode, which is
susceptible to damage by oxidising gases, gases for TIG welding these
steels are usually limited to pure argon or argon/helium mixtures.
Pureshield Argon
Argon is the most common gas for TIG welding both carbon and low
alloy steels. Arc initiation is easy but welding speeds are relatively slow.
Alushield Light & Alushield Universal
The addition of helium to argon creates a more fluid weld with better
penetration, improved fusion and faster welding speeds. The higher
helium mixtures should be used on thicker section materials. These
mixtures are widely used on automatic welding stations where high
welding speeds are the primary concern.
14 Gases for stainless steels
The right gases for all types of stainless steel.
Gases for stainless steels.
Stainless steel is usually defined as an iron-chromium alloy containing
at least 11% chromium. It often contains other elements such as silicon,
manganese, nickel, molybdenum, titanium and niobium. Most widely
used as corrosion-resistant engineering materials, it finds applications
in aggressive environments and at elevated temperatures.
Stainless steel is normally categorised into four main groups, and each
group is further sub-divided into specific alloys. The main groups are
austenitic, ferritic, martensitic and duplex.
• Austenitic stainless steels form the most widely used group,
accounting for around 70% of all stainless steels fabricated. They are
used in applications such as chemical processing, pharmaceuticals
manufacturing, food and brewing, and liquid gas storage. The
weldability of these grades is usually extremely good.
• Ferritic stainless steels are not as corrosion-resistant or as weldable
as austenitic stainless steels. They have high strength and good
high-temperature properties and are used for exhausts, catalytic
converters, air ducting systems and storage hoppers.
• Martensitic stainless steels are high-strength and are more difficult
to weld than other types of stainless steel. They are used for vehicle
chassis, railway wagons, mineral-handling equipment and paper and
pulping equipment.
• Duplex stainless steels combine the high strength of ferritic steels and
the corrosion-resistance of austenitic steels. They are used in corrosive
environments such as offshore and petrochemical plants, where the
integrity of the welded material is critical.
 Gases for stainless steels 15

Gases for MIG welding

Welding Spatter Reduced Porosity Fusion Penetration Ease of use Thickness

speed control surface oxide control range (mm)
Specshield 2.5% C02 1 to 8
Stainshield Heavy 3 to 15+
Stainshield Universal 1 to 12
Stainshield Light 1 to 5

The greater the number of dots, the better the gas performs.

MIG welding

MIG welding using solid wire is an important process for joining
stainless steels, usually with argon or argon/helium-based mixtures.
These gases also contain small amounts of an oxidising gas such as
oxygen or carbon dioxide to stabilise the arc. Carbon pickup can also be
a problem and this limits the amount of carbon dioxide that can be used
for low carbon grade (‘L’ grade) stainless steels to about 3%.
Stainshield Universal
This argon, helium and carbon dioxide mixture produces welds with
very good low temperature toughness values as well as excellent
corrosion resistance coupled with good penetration and low levels of
porosity. All these features can improve productivity, lower costs while
producing welds of the highest quality.

Specshield 2.5% C02
This mixture of argon and 2.5% carbon dioxide is a general purpose gas
mixture for MIG welding stainless steels. It gives a good wetting action
and produces smooth welds with little or no spatter and low surface
oxidation. This reduces the need to use aggressive chemical cleaning
agents after welding.
Some carbon pickup in the weld can occur but levels should not exceed
those required for welding low carbon grades in the weld metal.
The shielding gas operates well in dip, pulse and spray transfer
producing welds with very low surface oxidation. This mixture is
suitable for welding a wide range of material thicknesses at high
speeds again helping to improve productivity.
Stainshield Light
This high helium containing mixture is idea for pulse and dip transfer
welding. The high droplet frequency reduces spatter while increasing
fusion characteristics making it idea for welding in all positions.

Stainshield Heavy
This three component shielding gases containing argon, helium and
carbon dioxide it is best suited for spray and pulse welding on thicker
materials. The welds produced have low surface oxidation, excellent
corrosion resistance, good fusion and low reinforcement levels. All
these features help to reduce the number of rejects keeping costs low.

High welding speeds makes this product idea for both manual,
mechanised and robotic welding. This can lead to significant
improvements in productivity as well as keeping distortion low.
16 Gases for stainless steels

Gases for Flux-cored and Metal-cored arc welding

Welding Spatter Porosity Fusion Penetration Ease of use Thickness range

speed control control (mm)
Carbon dioxide 0 to >25
Specshield 20% C02 0 to >25

The greater the number of dots, the better the gas performs.

Flux-cored and metal-cored arc welding

Flux-cored arc welding of stainless steels is becoming increasingly

popular as high-quality tubular wires become available. As with steel-
cored wires, check the wire manufacturer’s recommendations to
ascertain which shielding gases are suitable.

Carbon dioxide
This gas is used with suitable stainless steel wires, large levels of fume
can be generated together with high spatter levels.

Specshield 20% C02

For use with flux-cored wires recommended for use with ‘mixed gas’. In
general it gives lower fume and spatter levels than pure carbon dioxide.
Lower fume levels can improve the workplace environment as well as
improve the well being of the workforce.
 Gases for stainless steels 17

Gases for TIG welding

Types of Welding Porosity Fusion Penetration Ease Thickness

stainless speed control of use range (mm)
steel
Pureshield Argon all 0 to 3
Stainshield TIG austenitic 0 to 10
Specshield 5% H2 austenitic 1 to 10+
Specshield 13% He, austenitic 1 to 10+
4% H2
Alushield Light all 0 to 10
Alushield Universal all 3 to 10+
Specshield 2.5% N2 duplex 0 to 10

The greater the number of dots, the better the gas performs.

TIG welding

TIG welding is a very common process for welding stainless steels
where high-quality welds with good surface finish are very important.
There is a greater number of shielding gas mixtures that can be used
for TIG welding stainless steel than for steel but not all gas mixtures are
suitable for all types, i.e. hydrogen-containing mixtures are suitable for
welding only austenitic types.
Pureshield Argon
Argon is the simplest gas for TIG welding stainless steels and nickel
alloys. Argon produces a clean welding arc, and is suitable for all grades
of stainless steel. However the arc is relatively cold and can suffer from
fusion and porosity problems as the material being welded gets thicker.
Stainshield TIG
This argon/hydrogen mixture is the preferred gas mixture for manual
welding of austenitic stainless steels. It gives a fluid weld pool and
produces a very clean bright weld reducing clean up time and costs.
Welders find this product very easy to use and with the better fusion
and lower defect rates the gas produces productivity is increased and
costs reduced.
Specshield 5% H2
This gas mixture has a higher hydrogen content than Stainshield TIG and
tends to be used for welding thicker section joints and although it can
be used manually it is best suited to automatic TIG welding of austenitic
stainless steels.
Specshield 5% H2 gives good weld penetration and fusion improving
productivity and lower costs. These attributes can also lead to a
reduction in size of weld preparation further lowering production costs.
Specshield 13%He, 4% H2
This argon, helium, hydrogen mixture has been specifically developed
for overcoming the problem of “cast-to-cast” variation when orbital
and automatically welding stainless steels. The addition of helium to
the mixture stiffens the arc column ensuring that equal levels of fusion
occur on each side of the weld pool dramatically reducing side wall
fusion defects resulting in less rework and cut outs.
Alushield Light
This shielding gas mixture is suitable for TIG welding all grades of
stainless steel with good welding speeds and penetration.
Specshield 2.5% N2
This mixture of argon and nitrogen is specifically designed for welding
duplex stainless steels. The nitrogen in the gas mixture helps to balance
the weld metal microstructure improving the in-service corrosion
performance, particularly pitting corrosion resistance.
Alushield Universal
This shielding gas mixture is suitable for TIG welding all grades of
stainless steel allows higher welding speeds and better penetration
than Alushield Light.
18 Gases for aluminium, copper and titanium alloys

The right gases for welding non-ferrous materials.

Gases for aluminium, copper and titanium alloys.

Gases for aluminium, copper and titanium alloys

Welding Spatter Porosity Fusion Penetration Ease of Thickness range Thickness range
speed control control use for MIG (mm) for TIG (mm)
Pureshield Argon 1 to 4 0 to 3
Alushield Light 1 to 6 1 to 6
Alushield Univiersal 3 to 10 3 to 9
Alushield Heavy 6 to 12+ 6 to 12+

The greater the number of dots, the better the gas performs.

There is a wide range of aluminium, copper and MIG/TIG

titanium alloys, and these are used in a variety of
industries such as aerospace, automotive, power
generation and petrochemical.
Both MIG and TIG welding are widely used for welding these non-
ferrous alloys. The choice of process is similar to that for other alloys
in that MIG tends to be used for high-productivity and TIG for high-
precision welding.

These non-ferrous alloys can exhibit a wide range of mechanical,
electrical and corrosion-resistant properties, depending on the alloy
system, but they all have one property in common – they oxidise very
easily during welding, and are sensitive to moisture and impurity pickup
by the weld. Because of this they are not as easy to weld as the steel
alloys, and good welding technique/procedures, together with good
housekeeping and cleanliness in and around the welding area, are
essential in order to weld these materials successfully.
The choice of shielding gas for welding these materials is very simple
in that only the inert gases are suitable as the major ingredients for
shielding gas mixtures. Consequently the most common gas mixtures
for both MIG and TIG welding aluminium, copper and titanium alloys are
pure argon, pure helium and mixtures of the two.
Small additions, (usually less than 0.05%) of oxidising gases have been
shown to be beneficial additions to argon/helium mixtures for welding
aluminium. However, these are specialised applications and require
welding engineering assessments. Titanium is very sensitive to oxygen
and nitrogen and may even require special low-impurity products.

Pureshield Argon
Best suited for welding thin sections. When used for MIG welding it can
give welds with high levels of reinforcement, poor fusion and porosity
when welding thicker sections. When MIG or TIG welding copper some
level of preheating is normally required.
Alushield Light
This mixture of argon/30% helium is used for both MIG and TIG welding
thin to medium section thicknesses. Fusion and penetration profiles are
improved over pure argon as are its gap bridging capabilities reducing
the chances of burn through. The addition of helium also helps to lower
the levels of porosity reducing defect rates.
Preheating will still be required for welding most thicknesses of copper
but temperatures will be lower than for argon.
Gases for aluminium, copper and titanium alloys 19
Alushield Universal
A 50% mixture of argon and helium it is used for manual and semi-
automatic MIG and TIG welding. It produces a more fluid weld pool
than Alushield Light, and so tends to be used on thicker components.
Fusion and penetration are excellent reducing defect rates, improving
productivity while reducing costs.
The high energy available means that little or no preheating is required
when welding thicker aluminium sections or copper and that in some
cases weld preparations can be reduced in size further reducing cost.
Alushield Heavy
A blend of 70% helium and 30% argon this mixture is most commonly
used for automatic MIG and TIG welding of thick section joints. It
produces a very fluid weld pool with excellent fusion and penetration
and is ideal for welding very thick aluminium sections and copper.
The fluid weld pool can both increase welding speeds as well as reduce
defect levels minimising the number of rejects created. Smaller weld
preparations will also further improve the economic advantage of using
such a shielding gas.
20 Plasma welding and cutting

The right gases for plasma processes.

Plasma welding and cutting.

Plasma cutting Gases for plasma welding

Materials Welding Fusion Penetration Thickness

speed range (mm)
Pureshield all 0 to 3
Argon
Alushield all 0 to 6
Light
Stainshield austenitic 0 to 8
TIG/ stainless
Specshield steel
5% H2

The greater the number of dots, the better the gas performs.

Plasma welding Plasma cutting

Plasma welding is a precision process involving a restricted welding arc,
and it is used for welding a wide range of materials. There are many gas
mixtures that can be used for plasma welding, but as with other welding
processes, it is important to choose a plasma shielding gas that does
not adversely affect the welding process or the weld metal produced.
Plasma cutting is used for cutting all metals and their alloys. In plasma
cutting there are two gas streams: one to generate the plasma and
the second to blow away the molten metal from the cut face. In some
machines, one gas is used for both tasks but in others, separate
gases are used.

Pureshield Argon
Argon is a standard shielding gas that can be used for plasma welding
of all materials.
Alushield Light
This mixture can be used for plasma welding of all materials usually in
thicker sections.
Stainshield TIG/Specshield 5% H2
These mixtures are primarily used for plasma welding of austenitic
stainless steels. The thicker the section of material to be welded, the
higher the hydrogen content in the plasma shielding gas.
The choice of both the plasma and shielding gas depends on the
material being cut and the condition of the cut surface required.
Choosing the wrong gas mixtures can create metallurgical defects close
to the cut face that can affect welding.
Specshield 35% H2
Used primarily for plasma cutting aluminium and stainless steel as the
plasma gas it produces a smoother cut face at higher speeds than other
mixtures. It is often used in combination with nitrogen or carbon dioxide
secondary gas.
 MIG brazing 21

The right gases for MIG brazing.

MIG brazing.

Gases for MIG brazing MIG brazing

Welding Spatter Bead Capillary Ease

speed control appearance action of use
Pureshield Argon
Specshield 2.5% C02
Alushield Light
Stainshield Heavy

MIG brazing

MIG brazing is a variation of the MIG welding process using copper-alloy
filler wires rather than wires with similar compositions to the parent
material. In MIG brazing, because no fusion takes place between the
parent material and the filler wire, the strength of the joint relies on the
level of capillary action of the filler.
Pureshield Argon
Argon is suitable for MIG brazing with both copper silicon (CuSi) and
aluminium bronze (CuAl) filler materials. However the travel speeds are
low and the weld bead appearance is not as good as with other gas
mixtures with high levels of reinforcement.

Standard MIG equipment is suitable for MIG brazing and usually the only
change required is to fit wire feed rollers suitable for the softer copper-
based wires. The filler wire is usually either a copper-silicon (CuSi) alloy
or copper-aluminium (CuAl – aluminium bronze) type.
Specshield 2.5% C02
The addition of a small amount of carbon dioxide to argon gives better
results than pure argon for both filler types. The carbon dioxide helps
stabilise the arc reducing spatter as well as producing a more even bead
shape, however some surface discolouration can occur especially with
aluminium bronze filler materials.

Alushield Light
The addition of helium to the shielding gas helps improve the fluidity
of the weld pool producing a more even weld bead shape at faster
welding speeds. The helium also helps with the capillary action
improving the bond between the surfaces being joined. This shielding
gas is often preferred when welding with aluminium bronze filler.

Stainshield Heavy
This shielding gas produces very smooth weld beads with little
reinforcement and virtually no spatter. Welding speeds are also very
high as the fluid weld pool gives the welder better control.
22 Purging or root backing

The right gases to protect the other side of the weld.

Purging or root backing.

Root runs on stainless steel pipe

Shielding gas Material

Argon all materials
Nitrogen carbon and low-alloy steels (not high-strength
(oxygen free) fine-grained steels);
austenitic, duplex and super-duplex stainless steels
Stainshield TIG austenitic stainless steels
Specshield 5% H2
Specshield 2.5% N2 austenitic stainless steels (not Ti-stabilised)
duplex and super-duplex stainless steels

When welding takes place, the temperature of Gases

both the parent material and filler rises above the
The most common gases used for purging are argon and nitrogen, but
temperature at which oxidation takes place. The mixtures of argon/hydrogen and nitrogen/hydrogen can be used if the
shielding gas protects the front of the weld from material is not susceptible to nitrogen or hydrogen attack.

atmospheric contamination but if no purging or
root backing is carried out on the back of the weld,
it will oxidise.
Purging is usually carried out when the welded material is going to be
used for its corrosion-resisting qualities, such as stainless steels and
some nickel alloys, or when the material will oxidise very easily during
welding, such as with aluminium and titanium alloys. If root purging is
not done, it can significantly reduce the working life of the component
or in the worst case lead to its failure in service.
Purging is achieved by passing a dry stream of an inert, low-reactivity
or reducing gas over the reverse side of the weld area to exclude the
air, preventing oxidation from taking place. It is important to choose the
purging gas with care. For some metals that oxidise very readily (such
as titanium), it may be necessary to place the component in a chamber
filled with the purge gas to ensure that oxidation does not take place.
Argon is widely used for weld purging due to its inert nature. It will give
satisfactory results on all materials because no compounds are formed.
Nitrogen is also widely used. However, care should be exercised
because some materials (such as aluminium) are sensitive to nitride
formation and this can reduce the corrosion-resistance characteristics.
Also, nitrogen is an austenite stabiliser in stainless steels and
adsorption into the weld areas could produce an unacceptable
microstructure.
Hydrogen is added to argon primarily to improve its oxygen-scavenging
characteristics. Gas mixtures such as Stainshield TIG and Specshield 5%
H2 are frequently used in high-quality applications where only very low
levels of oxidation can be tolerated. These mixtures are only used with
materials that are not susceptible to hydrogen attack, such as austenitic
stainless steels.
 Purging or root backing 23

With root backing Without root backing

Practical advice Safety

In many applications, it is necessary to maintain a low oxygen When using purging gases containing more than 5% hydrogen, it is
concentration during welding. Just what level of oxygen can be recommended to burn off the hydrogen to prevent build-up. However,
tolerated depends largely on the material being welded and the type of hydrogen burns with a nearly invisible flame, and it is recommended
service the component will undergo. that a wire mesh cage be fitted around the flare stack to prevent an
operator accidentally coming into contact with the flame.
Technical advice should be sought if you are unsure of the oxygen level
required but as a general guide the following may be useful: When purging, the volumes of inert or unreactive gases used tend to
be quite high and this significantly increases the risk of asphyxiation in
• For carbon and many low-alloy steels, for most applications, back the areas around the welding station. It is therefore important always
purging is not required. to check the working environment ensure to that there is adequate
• For carbon and low-alloy steels, when back or pipe purging is oxygen present to support breathing.
required, a value of 1% O2 is often considered acceptable.
• For many applications with stainless steel, an oxygen level of 0.01%
(100ppm) is satisfactory but some surface oxidation will occur.
• For stainless steels for extreme service conditions, a level of 20ppm O2
may be necessary to prevent pitting corrosion or subsequent stress-
corrosion cracking.
• For nickel alloys, between 25 and 50ppm O2 may be stipulated.
• For reactive metals like titanium and zirconium, as little as 5 or 10ppm
O2 is normally required to prevent embrittlement.
• For semiconductor applications, impurity levels of 1ppm are
generally required.
• The level of oxygen after purging can be estimated from flow-rate/
flow-time charts available for different-purity purging gases, but it is
more accurate to use an oxygen analyser.
24 Frequently asked questions
Are you using the right gases correctly?
Frequently asked questions.
Here are a few of the many thousands of questions
BOC engineers are asked every year. Some you will
know the answer to, for others, the answer may not
be what you were expecting. Some you may have
been waiting years to have an answer to.
Can my gases have separated in the cylinder?
Gases don’t separate in a cylinder. In a cylinder the gas molecules are
constantly in motion and this ensures total mixing. If gases didn’t stay
mixed, air would have separated into oxygen and nitrogen by now!
Why am I getting holes in my welds?
Holes (porosity) are usually caused by gas entrapment inside the
cooling weld metal. While gases such as nitrogen are one of the main
causes of porosity, other sources such as water, oil and grease on the
material can be as much of a problem.
The main causes of porosity are:
• too high or too low a flow of shielding gas – too high and air is
entrained into the shield; too low and the gas can’t protect the cooling
weld metal from the atmosphere.
• poor welder technique – too long a stick-out or bad torch angle.
• incorrect choice of shielding gas – shielding gases containing
hydrogen and/or nitrogen are beneficial for some materials but can
cause porosity in others.
• poorly maintained equipment – if hose fittings are not tightened or if
there are gas leaks in the power source or torch, air can be entrained
into the shielding gas. Also some types of hose are permeable and can
allow moisture to enter the shielding gas. Surface contamination – oil,
grease, water and other contamination on the welded component –
can add hydrogen into the weld metal.
This is not an exhaustive list but most causes of porosity are caused by
poor housekeeping and/or poor welding procedures.
Why can I not use pure argon for MIG welding steels?
While it is possible to MIG-weld steels with pure argon, the arc
produced is very unstable and erratic, and the resultant weld will have
a lot of spatter and an unsatisfactory penetration profile.
When MIG welding steels, a small amount of oxidising gas (either
carbon dioxide or oxygen) is needed to help to stabilise the arc and
produce sound welds.

Why am I getting a lot of spatter on my welds?
There are several causes of spatter, but the most common are:
• using unstable welding conditions – incorrect voltage for a given
welding current
• poor welder technique – too long a stick-out or bad torch angle
• surface contamination on component – oil, grease, moisture
• surface coatings such as paint and zinc galvanising
• using carbon dioxide as the shielding gas – mixed gases are more
stable and produce less spatter
Training the welder to set good welding conditions and clean the
component properly can eliminate many of the problems.
I get cracking when welding stainless steels. Why?
There are two main types of cracking in stainless steels: ‘hot cracking’
and ‘cold cracking’.
Hot cracking, properly called ‘solidification cracking’, tends to be a
problem in austenitic stainless steels. It is called ‘hot cracking’ as it
tends to occur immediately after welding while the weld is still hot.
Weld-metal solidification cracking is more likely in fully austenitic
structures which are more crack-sensitive than those containing a small
amount of ferrite.
Frequently asked questions 25
The best way to prevent cracking is to choose a consumable which has a
high enough ferrite content to ensure that the weld metal does not crack.
Cold cracking, properly called ‘hydrogen cracking’, occurs in welds that
are intolerant of hydrogen (e.g. martensitic stainless steels). Hydrogen
dissolves in the weld metal while it is molten then after solidification it
diffuses to small defects in the weld and hydrogen gas forms, building up
in pressure as the weld cools. Then, when the pressure is sufficiently high
and the weld is cool and more brittle, this internal pressure can cause the
weld to crack. This may not occur until many hours after welding.
What causes the sooty deposit when welding aluminium?
This sooty deposit is not soot (carbon) at all, but a form of aluminium oxide.
When welding occurs, some of the parent material and filler wire is
volatilised by the welding arc. As this fine metal vapour leaves the
area covered by the shielding gas, it reacts with air, forming aluminium
oxide that condenses on the component being welded. The higher the
welding current used, the greater the amount of oxide produced.
It is not always possible to eliminate this problem but altering the torch
angle and ensuring correct shielding gas coverage can minimise the
effect. Also, if the weld is cleaned immediately after welding, the oxide
is much easier to remove than if it is left until the weld is cold.
26 Health and safety

Hazards associated with welding.

Health and safety.

Electromagnetic radiation

Wavelength (nm)
100

280

315

400

760

1400

3000

106
Arc eye Retinal burns Corneal burns
Blue light

Cataracts

Colour and night-

Erythema vision degradation
UV-C

UV-B

UV-A

VISIBLE

IR-A

IR-B

IR-C

The welding environment can be a hazardous place Radiation hazards

for the untrained and unobservant. Welding, cutting
Arc welding and cutting emit electromagnetic radiation in the form of
and allied processes present numerous occupational ultraviolet (UV), visible light and infrared (IR) radiation. The potential
hazards to welders and others. Everybody has a effect of radiation on the body depends on the type and intensity of the
radiation, the distance you are from it and the duration of exposure.
responsibility to work safely and to not endanger
themselves or any other person at work. Non-ionising radiation from welding/cutting processes can cause
damage to the skin and eyes. UV radiation in particular can cause burns
Being aware of the possible hazards and how best to avoid them is to unprotected skin and eyes (arc eye).
paramount in reducing the risk associated with these hazards. The main
welding-related hazards encountered by welders include: Radiation from electric welding arcs is usually apparent but arc flashes
• electricity can occur without warning. The effects of IR and UV radiation are not
• radiation normally felt until some time after exposure.
• heat, flames, fire, explosion
• noise
• welding fumes Heat, flames, fire and explosion
• solvents
A burn is a hazard that welders face every working day because
These are not the only hazards faced in the welding workshop and welding is a process that frequently involves heat, flames, molten metal
people working in this environment must always remain vigilant. and high-temperature welding arcs. Burns may occur to the skin, or,
potentially very seriously, to the eyes.

Electrical hazards Fire and explosion are serious hazards in the welding environment.
Heat and flames can result in fire or even explosion in the presence of
Touching live electrical equipment or components, including the combustible materials, dust, flammable liquids, gases or vapours.
electrode and the workpiece, can result in burn injuries or, more
seriously, electric shock. Electric shock can kill by direct action on the
body. It can also cause you to fall if working at height.

Noise
Noise is an everyday occurrence in an industrial workshop. All welding
and cutting processes generate noise but some are much noisier than
are others. Ancillary processes like grinding, chipping, gouging and
hammering also generate varying levels of noise. Exposure to noise
over a period of time can result in impairment or loss of hearing.
Welding fume
All welding processes generate welding fume but some produce very
little fume while others produce much more. Welding fume consists of
particulate fume – the cloud of smoke you can see rising, and gaseous
fume, which you cannot see but can sometimes smell. In most cases,
welding fume is formed close to the arc and near the welder, but some of
the gaseous fume (i.e. ozone) can be generated well away from the arc.
The potential effect on the body of exposure to welding or cutting fume
depends mainly on the amount of fume produced, what is in it and the
length of time the worker is exposed to the fume. Whilst all components
of welding or cutting fume may present a risk to health given a high
enough concentration, some present a greater hazard than others.
Health and safety 27
Solvents
Solvents used in welding industry may be flammable, contain
constituents that are flammable, or they may be non-flammable.
The most frequently encountered flammable solvents are acetone,
petroleum ether and white spirits.
Some solvents break down under the action of the welding arc to form
toxic or irritant by-products, the most toxic of these being phosgene.
Precautions
Controls
Good general ventilation, and/or local fume extraction should be used
to control the fumes and gases produced during welding to below their
individual recognised exposure limits when measured in the welder’s
and co-workers’ breathing zone.
In confined spaces where ventilation is not adequate, it may be
necessary to use an air-fed breathing system. Where fume levels exceed
the recognised exposure limits, respiratory protection may be required.
Personal protection
Due to the hazards associated with welding, cutting and other
manufacturing processes, welders and co-workers in the vicinity should
wear the correct protective clothing, hearing and eye protection as
specified by local standards.
28 Supply options
Providing you with the right gas.
Supply options.
Shielding gases can be supplied in various ways.
We are happy to advise you on the best choice for
your needs.
Cylinders
Cylinders are the most common way that our customers receive their
shielding gases. In the cylinder, the gas is held at high pressure; this
can be anywhere from 150 to 300 bar, dependent on the shielding gas
composition and the pressure rating of the cylinder itself.
Some shielding gases are also available in different sizes of cylinder to
best suit your needs. However, the most common cylinder size is 50 litres,
which holds about 10m3 of gas, dependent on the pressure to which it is
filled. So for a typical shielding-gas flow-rate of 15 litres per minute, this
size of cylinder will last for about 11 hours of continuous welding.
Cylinder bundles
Cylinder bundles are ideal for customers who use high-productivity
processes and don’t want to waste time changing cylinders, or who
have several welders using the same shielding gas from a pipeline.
Cylinder bundles typically contain 12 to 15 of these 50-litre cylinders
connected together.
You simply connect to the bundle outlet as if it were a single cylinder.
All bundles are designed to be handled using a forklift truck and some
products are also designed to be craned into place. Please check with
your Linde representative which is suitable for you.
Liquid cylinders
Cryogenic liquid cylinders are ideal for customers with similar gas
require­ments to those using cylinder bundles but who don’t have the
space. These vacuum-insulated cylinders stand about the same height
as a 50-litre cylinder and hold about the same amount of gas as a
cylinder bundle. However in this case, the ‘gas’ is stored as a cryogenic
(cold) liquid.
Although not available for shielding gas mixtures, liquid cylinders are
available for a range of pure gases such as argon, oxygen, carbon
dioxide and nitrogen. When used in conjunction with a mixing system,
liquid cylinders can be used to produce many of the BASE product line
shielding gases.
In some geographies, liquid cylinders can be refilled by topping up on
site, in addition to the normal full-for-empty service.
 Supply options 29

Liquid tanks Mixing systems

Liquid tanks are best suited to customers who require large volumes
of gas. These cryogenic tanks are fixed on concrete plinths at the
customers’ sites, and are filled periodically by liquid tanker trucks. The
largest liquid tanks hold over 60,000m3 of gas, which is enough to
last one welder over 2.5 years. These vessels are best suited to large
factories with more than about 25 welders or welding stations.
Again they are available for a range of pure gases such as argon,
oxygen, carbon dioxide and nitrogen. A mixing system is required to
create the required shielding gas and a pipeline is needed to deliver it
to where the welding is taking place.
Mixing systems are available in a range of capacities to suit your
applications. These precision products can be supplied ready to produce
a fixed composition or with the flexibility to make different gas mixtures
either manually or by computer control.
Our trained engineers will be happy to size your installation for you,
ensuring that you have the right package for your present and
future needs.

Steel cylinders Liquid cylinders

Capacity (litre) Filling* (m3) Content* (m3)

~10 2.0–2.4 ~106.8–141.6
~20 4.0–4.7
~50 9.9–11.8

*Volume of gas in the cylinder depends on the type of gas *Volume of gas in the cylinder depends on the type of gas

Cylinder bundles Liquid upright tanks

Content* (m3) Content* (l)

110–175 ~600–75,000

*Volume of gas in the bundle depends on the type of gas *Volume of liquid in the tank depends on its size
30 Services
Complementing the right gas.
Services.
BOC provides a broad range of services
complementing your choice of gas. Our services
portfolio has been developed to meet your needs
as our customer. The portfolio can be broken down
into four interlinked segments:
3 Administrative efficiency
3 Supply reliability
3 Quality and safety
3 Process know-how
Administrative efficiency
Not only do we deliver high-quality products as standard, but we make
it simpler and easier for you to order your gas when you need it.
• Customer Service Centre – BOC offers you a one-stop-shop for all your
gas supplies, equipment needs, associated products and services
you need for your business. We are for you all day, everyday - so
whenever you need assistance we are just at the end of the phone.
Supply reliability
It is our goal is to eliminate all unscheduled interruptions to your
delivery, ensuring you get the right gases when you want them.
• Extra Delivery Services – we know you can’t always predict exactly when
and how much gas you will need. Express and emergency delivery,
delivery to point-of-use and cylinder connection are some of our service
offers available to you. That’s why we deliver when it suits your needs.
• Complete Supply Options – Whatever the process used we have a supply
mode to meet your needs. Compressed gas cylinders, mini bulk and
bulk cryogenic gases - We supply them all without any effort to you.
Quality and safety
Safety is a priority for BOC and most likely for you too. BOC can provide
you with know-how in the safe use of your shielding gases.
• Safety Training – these are practical courses designed for the users of
gases. These can be delivered at a customer site or at open workshops
enabling all levels of personnel to meet their individual needs.
• Gas Analysis – professional analysis of gas in the lab or on site
guarantees the high and consistent quality you need in your processes.
• Preventive maintenance contracts – we offer a regular check of your
gas-supply system, to ensure its safe operation and, if required, to
maintain and repair the system.
Process know-how
The BOC is part of a global solution-provider committed to the welding
industry. With our outstanding global team of application engineers, we
have high competence in all shielding gas processes.
• Application training – you can benefit from our experience in welding
and cutting applications to ensure that the skill levels of your workers
are as high as possible.
• Process consultation – our application engineers can look at your gas
consumption and optimise it for your processes.
 Services 31

Know the right gas cylinder colours.

The cylinder label is the primary method of identifying for any gas; Cylinder colours
the cylinder colour should only be used a guide. If a cylinder does not
have a cylinder label, it should not be used but should be returned Gases
immediately to the supplier. Argon

Nitrogen

Carbon Dioxide

Helium

Argon + Carbon Dioxide mixtures

Argon + Oxygen mixtures

Argon + Helium mixtures

Argon + Nitrogen mixtures

Argon + Hydrogen mixtures

Nitrogen + Hydrogen mixtures

Cylinder body colour is not covered by the standard and can be any colour
BOC – turning ideas into solutions
BOC is a member of The Linde Group, the leading global gases and engineering company. BOC is the UK’s largest provider of
industrial, specialist and medical gases, as well as related products and services. As a leader in the application of technology,
we are constantly looking for new ways to provide our customers with high quality products and innovative solutions.

At BOC we help our customers to create added value, clearly discernible competitive advantage and hence greater profitability.
To achieve this we have a comprehensive range of products and services, and technical support which can be customised to
meet the individual requirements of our clients.

To keep ahead of the competition in today’s market, you need a partner for whom quality, service, process and productivity
optimisation are an integral part of customer support. We are there for you and with you, helping to build your success.

BOC’s reputation has been forged through partnerships – with customers, with relevant regulatory authorities and with key
suppliers. In this way, we deliver comprehensive and consistent benefits to you.

BOC – world-leading knowledge and resources adapted to local requirements.

For enquiries please contact:

BOC BOC Ireland

Customer Service Centre, PO Box 201,
Priestley Road, Worsley, Bluebell, Dublin 12,
Manchester M28 2UT Republic of Ireland

Tel 0800 111 333 Tel 1890 355 255

Fax 0800 111 555 Fax (0)1 409 1801

Email custserv@boc.com Email irelandsales@boc.com

GAS/403435/APUK/0610

BOC
The Priestley Centre, 10 Priestley Road, The Surrey Research Park, Guildford, Surrey GU2 7XY, United Kingdom
Tel +44 1483 579 857, Fax +44 1483 505 211, www.BOConline.co.uk
The stripe symbol and the letters BOC are registered trade marks of The BOC Group Limited. Both BOC Limited and The BOC Group Limited are
members of The Linde Group, the parent company of which is Linde AG. Reproduction without permission is strictly prohibited. © BOC Limited 2010